With over 90% reduction in near-miss violations, Tata Steel enhanced its safety standards in their Durgapur Steel Plant
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Identify Areas Of Risk With Scaling Workforce
The Durgapur Steel Plant (DSP), one of the country’s first steel plants, a vital unit of the Steel Authority of India Limited (SAIL), exemplifies India's progress in industrial development. Situated in Durgapur, West Bengal, DSP is known for its integrated steel manufacturing capabilities, performs multiple tasks, such as raw material handling, iron making, building structural steel rods, among others.
Given such large-scale sourcing of minerals, and subsequent metal production, the involvement of complex industrial vehicles are understandable. But, owing to its proximity to dense human inhabitation, the possibility of machine-pedestrian as well as machine-machine collision equally increases. While industrial sites usually include large vehicles, such as, HEMM, LMV and Dumpers, the DSP region had cargo train movement for transporting finished materials like billets, within the premises. Even the slightest accident involving a cargo train would result in fatalities, economic losses, production stagnancy and reputational damage.
To ensure safety, SAIL DSP authorities had previously installed timer-based traffic lights in the intersection of the railway tracks and public roads. Moreover, a traffic personnel was simultaneously put in charge as an added layer of protection and to facilitate responsible traffic flow.
But, even after taking precautionary measurements, the region witnessed near-misses where pedestrians or civilian vehicles narrowly missing collision with the cargo train. These happened due to two specific reasons: absence of traffic personnel at certain moments and lack of an advanced solution to stop vehicular or pedestrian movements across the tracks.
"Bidaal’s system has not only been highly effective in our Durgapur plant premises but has been equally robust throughout. Though there have been minor issues, but the team has put utmost effort to ensure the proper functioning of the system, providing great after-sales service."
Tapan Kumar RoyGeneral Manager, Electrical and Automation, SAIL Durgapur Steel Plant
Identify Areas Of Risk With Scaling Workforce
To upgrade the present solution at DSP SAIL, Bidaal implemented its patented solution SMILE replacing the outdated technology that was controlling the traffic movement. The solution included strategic positioning of ultrasonic sensors across the cross-points, which were linked with signal controllers. The smart sensors functioned based on the movement of the initial and final sections of the cargo train, and relayed signals accordingly to the controllers.
The controllers were designed to operate the existing LED traffic lights placed at the intersection of the rail-roads and the public roads. Moreover, to accommodate the possibility of reverse movement of the train wagons, a buffer period of few seconds was implemented in the signaling system.
While having a traffic personnel added an extra layer of protection, it was not the most effective solution in harsh weather conditions. Comparatively, the equipment deployed by Bidaal was not only meant to provide relentless results even in harsh weather conditions, but was also IP65 rated, designed to withstand rough environment.
Lastly, SAIL DSP authorities stated the need to have a solution where a potential system failure can be detected spontaneously. The processing unit was designed accordingly to inform the designated authorities about any system failures that could result in the entire system to falter.
80% Reduction In Incidents
The deployment of Bidaal’s solution was effective for DSP SAIL in three key areas: increasing the overall productivity, economical growth, and decrease in potential accidents.
The deployment of Bidaal’s SMILE system brought a substantial reduction in the risk of accidents at the Durgapur Steel Plant. By automating the detection of cargo train movement and controlling traffic flow through smart ultrasonic sensors, the chances of machine-pedestrian and machine-machine collisions were significantly minimized. This proactive safety approach helped prevent incidents that could otherwise result in fatalities, legal liabilities, and reputational damage.
With the intelligent traffic control system in place, delays caused by manual operations or absent traffic personnel were eliminated. The precise synchronization between sensor inputs and traffic light outputs allowed for smoother movement of vehicles and cargo trains within the plant premises. By reducing idle time and ensuring uninterrupted flow of materials, the solution contributed directly to improving operational efficiency and maintaining production timelines—an essential aspect of overall plant productivity.
The improved safety and streamlined logistics translated into tangible economic benefits for DSP SAIL. Avoidance of accidents meant reduced downtime, lower repair and compensation costs, and uninterrupted supply chain activity. Moreover, the long-term reliability of the system minimized maintenance expenses. By enhancing safety, efficiency, and system uptime, the solution supported sustainable economic growth and allowed resources to be focused on core manufacturing activities rather than incident management or operational disruptions.
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